FlexArc® - Robotic Arc-Welding CellsModular Solutions to Increase your Productivity

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ABB Inc.1250 Brown RoadAuburn Hills, MI 48326248-391-9000

www.abb.com/robotics

Standard FlexArc Models

Available FlexArc Models

FlexArc with A-Type Positioners - IRBP A FlexArc with C-Type Positioners - IRBP CRobot IRB1520ID, IRB1600(ID), IRB2600(ID), IRB4600 Robot IRB 1520ID, IRB1600(ID), IRB2600(ID), IRB4600Number of Robots 1 to 2 Number of Robots 1-2 (up to 3 on request)Positioner IRBP A-250, IRBP A-500, IRBP A-750 Positioner IRBP C-500, IRBP C-1000Handling Capacity Max 750 kg Handling Capacity Max 1000 kgWelding Equipment Fronius, Miller, Lincoln, SKS Welding Equipment Fronius, Miller, Lincoln, SKSTorch Equipment Tregaskis, Binzel, Dinse Torch Equipment Tregaskis, Binzel, Dinse

Safety EquipmentComplete System of Safety Features - safety fencing, light curtains, laser scanner, roll doors, safety locks, safety PLC

Safety EquipmentComplete System of Safety Features - safety fencing, light curtains, laser scanner, roll doors, safety locks, safety PLC

FlexArc with K-Type Positioners - IRBP K FlexArc with D-Type Positioners - IRBP DRobot IRB 1520ID, IRB1600(ID), IRB2600(ID), IRB4600 Robot IRB 1520ID, IRB1600(ID), IRB2600(ID), IRB4600Number of Robots 1-2 (up to 4 on request) Number of Robots 1-2 (up to 3 on request)Positioner IRBP K-300, IRBP K-600, IRBP K-1000 Positioner IRBP D-300, IRBP D-600Handling Capacity Max 1000 kg Handling Capacity Max 600 kgWelding Equipment Fronius, Miller, Lincoln, SKS Welding Equipment Fronius, Miller, Lincoln, SKSTorch Equipment Tregaskis, Binzel, Dinse, Torch Equipment Tregaskis, Binzel, Dinse

Safety EquipmentComplete System of Safety Features - safety fencing, light curtains, laser scanner, roll doors, safety locks, safety PLC

Safety EquipmentComplete System of Safety Features - safety fencing, light curtains, laser scanner, roll doors, safety locks, safety PLC

FlexArc with B-Type Positioners - IRBP B FlexArc with R-Type Positioners - IRBP RRobot IRB 1520ID, IRB1600(ID), IRB2600(ID), IRB4600 Robot IRB 1520ID, IRB1600(ID), IRB2600(ID), IRB4600Number of Robots 1 to 2 Number of Robots 1-2 (up to 4 on request)Positioner IRBP B-250, IRBP B-500, IRBP B-750 Positioner IRBP R-300, IRBP R-600, IRBP R-1000Handling Capacity Max 750 kg Handling Capacity Max 1000 kgWelding Equipment Fronius, Miller, Lincoln, SKS Welding Equipment Fronius, Miller, Lincoln, ESAB, SKSTorch Equipment Tregaskis, Binzel, Dinse Torch Equipment Tregaskis, Binzel, Dinse, SKS

Safety EquipmentComplete System of Safety Features - safety fencing, light curtains, laser scanner, roll doors, safety locks, safety PLC

Safety EquipmentComplete System of Safety Features - safety fencing, light curtains, laser scanner, roll doors, safety locks, safety PLC

FlexArc U2, Fixed Station Cell ArcPac U2, Fixed Station CellRobot IRB 1520ID, IRB1600(ID), IRB2600(ID) Robot IRB 1520ID, IRB1600(ID)Number of Robots 1 Number of Robots 1Positioner 2x Fixed Table Positioner 2x Fixed Table, Optional 300L Per SideHandling Capacity Max 300 kg Handling Capacity 225 Kg Per TableWelding Equipment Fronius, Miller Welding Equipment Fronius, Miller Torch Equipment Tregaskis, Binzel, Dinse Torch Equipment Tregaskis Air Cooled LSR

Safety EquipmentComplete System of Safety Features - guarding, manual station doors, maintenance door, Electronic position switch (EPS)

Safety EquipmentComplete System of Safety Features - guarding, manual station doors, maintenance door, Electronic position switch (EPS)

Standard Configuration Optional Configuration

Platform, Fencing with the touch service window, service door, robots, pedestals, positioner, controller, power distribution panel

Robot Safety

IRB 1520ID, 1600, 1600ID, 2600, 2600ID, 4600

Verical/Horizontal Light Curtains

Roll Down Door, Two-Hand Control

Welding Power Source Welding Power Sources Tool Service

Welding Torch According to end-user requirements Service Center for Torches

Operator Panel Seam Finding Torch Cleaner

Safety Equipment, PNOZ Multi including Vertical Light Curtains SmartTac, WeldGuide III, BullsEye®; TCP Calibration

Software 1-D Laser SmartTac Wire Cutter

Robotware Arc Other Options Welding Torches

FlexPendant - Graphical User Interface for Operators PLC, OP Panels According to end-user requirements

Welding Error Handler Manual Jog Fume Extraction Hood

Production Monitoring Full Air and Gas Distribution Panel Welding Station Only Coverage

Production Manager Programming Platform Coverage of Welding Stations and Load/Unload Station

IRB 1520ID IRB 1600ID IRB 2600ID IRB 4600

IRBP L Motor and Gear Unit Sets IRBP C 500 IRBP R 300

IRBP K 600 IRBP D 600 IRBP B 250 IRBP A 250

FlexArcs - Configured to Match Your NeedsA New Dimension in Robotic Arc Welding The Ultimate Productivity Tools

Production MonitoringThe robot system automatically monitors weld lengths and number of welds made on a component and reports with a screen message and a warning light if a part was not produced according to the original specification. This enables the operator to take immediate action to repair or reject the faulty component.

Customer-Specific FlexPendant Screens

Whatever the requirement, the ABB IRC5 Platform offers the ability to easily make Teach Pendant screens specific to your needs. Whether it’s a quick model change, enhanced operator interface, or an on-the-fly program adjustment: FlexPendant interface is there to make you more productive.

FlexArc® - A New Generation of Welding CellsFlexArc® is a new generation of standardized welding cells, which are designed to deliver cost-effective, state of-the-art robotic welding operations. All cells deliver maximum performance whilst making optimum use of available space. The basic options feature either a single robot, or two robots with Multi-Move, a choice of ABB positioners from our extensive range and welding equipment to suit your needs. All equipment is installed on the common platform, which provides shorter commisioning time and relocation within the production facilities.The cells are equipped with centralized power distribution - all components are supplied from one source; this means that only one power supply cable for the whole cell is necessary.

FlexArc® Advantages

• Low investment cost• Intuitive graphical user interface for operators • Reduced downtime thanks to improved error

handling• Higher quality through automatic production and

process monitoring• Improved cost-efficiency thanks to global

standardization• Short delivery times• Proven two-station principle (loading and welding)• Off-line programming for fast and easy

implementation• Improved workspace safety• Designed and built to last

Optimal productivity requires equipment that combines effective operation with maximum cost-efficiency. Modular, pre-engineered robot cells are an established way of providing this type of solution.

Boosting your workflowFlexArc® features the FlexPendant graphical user interface, which not only provides operators with an overview of the status of the cell, but also important quality and production data. The interface allows the operator to communicate effectively with all of the functions within a cell and access all information regarding cell performance, including the status of the robot and controller along with other functions such as roll-down door control. With minimum training, the user can organize the welding operation into a series of work steps. The operator has all the information necessary to keep track of the number of parts produced, cycle times, the number of welds produced and the individual weld length. Easy implementation makes the FlexArc® standard approach the natural choice for “plug-and-produce” operations.

FlexArc® is the Most Effective Solution in your industry

• General Industry:Door modules, grids, switch boards, printing units, steel furniture, shopping carts, racks, compressors, lawnmowers, two wheelers and construction and agricultural equipment components

• Automotive Industry:Cross members, engine cradles, door modules, exhaust systems, brake components, car seats, wheels, axles, dash boards and more

Virtual FlexArc® with RobotStudio• Train operators on the virtual cell without losing valuable production time on the real cell• Generate programs off-line before your new system arrives• Generate programs for new parts while the real cell continues to produce uninterrupted• Design the weld fixture around an optimized robot welding program• Verify that tooling provides proper weld torch access to the weld seam prior to building the weld fixture

BullsEye® - Tool Calibration and Automated CheckThe patented BullsEye® allows accurate definition and automatic updating of the Tool Center Point (TCP) and the torch angle.

Automatic Error HandlingThere is no need to enter the cell when a weld error occurs. At the push of a button the robot will go to the service pocket in the guard, where the operator can service the welding gun (e.g. changing the contact tip etc.) This saves valuable production time and gives an increase in productivity.

Navigator

The Navigator functionality includes cell calibration for off-line generated programs, tooling calibration (including integrated coordinated measurement functionality) and cell self diagnostics.

Tools for Quality and Increased Uptime

FlexArc 600K Single IRB2600IDFlexArc 300R Dual IRB1600ID

FlexArc 500B Single IRB2600ID

FlexArc 500C Single IRB1520ID

FlexArc U2 Fixed Station Cell ArcPack U2 Fixed Station Cell